A new form of plastic could change the way limb conditions and injuries are treated – and it is being developed right here in Coventry.

torc2, based at Bilton Industrial Estate, has protected the intellectual property of the flexible, durable compound that can be reshaped at temperatures that are safe for patients.

It is hoped that the material could be used for splints and support devices to treat conditions such as cerebral palsy, talipes (club foot) and hip dysplasia. It could also be developed to make reshapable liners for lower limb prosthetics.

Gary Blundell and Ron Taylor are part of the team that runs the firm.

Gary explained: “The key property of our torc material is the fact it can be softened at low temperatures.

“It can be reshaped directly on the patient at around 55 degrees and, therefore, the types of products we are looking at can be altered to exactly fit the patient very quickly, easily and without waste.

The torc polymer blend in various forms - granules, plaques in various colours and as a miniature prototype model, produced on a modified laboratory 3D printer

“There is a whole range of supports and splints required for a number of conditions, many of which have to be changed and altered regularly. The properties within torc material allows that to happen very quickly and easily.

“In some cases, spica casts being a typical example, it can cut out the need for extra trips to the operating theatre – which is a huge cost saving to the NHS and much better for the patient.”

Gary and Ron have a background in engineering and plastics and originally developed the new material as a potential replacement for Plaster of Paris casts.

Jeremy Moore, of the CWLEP Growth Hub, said: “From my first conversations with Gary and Ron, I could see the passion they have for this exciting new material. They are doing exactly the right thing, too, by listening to the advice of experts from the medical profession.

“I am pleased that we've been able to help them reach this stage and it would be great to see this innovation used the world over, knowing it started right here in our area.”

Gary said the next step is to upscale their current lab micro 3D printing process to enable production of full-size devices for clinical trials – for which they are seeking additional funding.